Energy-efficient window coatings transmissible to wireless communication signals and methods of fabricating thereof

Abstract

Provided are novel energy-efficient signal-transparent window assemblies and methods of fabricating thereof. These window assemblies are specifically configured to allow selective penetration of electromagnetic wavelengths greater than 0.5 millimeters, representing current and future wireless signal spectrum. This signal penetration is provided while IR-blocking properties are retained. Furthermore, the window assemblies remain substantially transparent within the visible spectrum with no specific features detectable to the naked eye. This unique performance is achieved by patterning conductive layers such that the conductive layer edges remain protected during most fabrication steps and the fabrication. As such, the conductive layers are encapsulated and separated from the environment while retaining separation between individual disjoined structures of these layers. For example, a barrier layer and/or a dielectric layer may extend over the conductive layer edge. The patterning is achieved by forming photoresist structures on the substrate and depositing a low-E stack over these photoresist structures.

What is claimed is: 
     
       1. An energy-efficient signal-transparent window assembly comprising:
 a window substrate; 
 a first dielectric layer, disposed over the window substrate; 
 a conductive layer, disposed over the first dielectric layer such that the first dielectric layer is disposed between the conductive layer and the window substrate; 
 a barrier layer, disposed over the conductive layer such that the conductive layer is disposed between the first dielectric layer and the barrier layer, wherein the barrier layer comprises nickel or titanium; and 
 a second dielectric layer, disposed over the barrier layer such that the barrier layer is positioned between the second dielectric layer and the conductive layer,
 wherein the first dielectric layer, the conductive layer, the barrier layer, and the second dielectric layer form multiple disjoined stacks, the multiple disjoined stacks separated by openings extending to the window substrate, the openings forming a pattern, 
 wherein the conductive layer is formed by multiple disjoined structures, each positioned in one of the multiple disjoined stacks, 
 wherein the barrier layer in each of the multiple disjoined stacks extends to the window substrate and blocks the multiple disjoined structures of the conductive layer from the openings, 
 wherein the barrier layer or the second dielectric layer forms sidewalls, each sidewall blocking and separating a corresponding one of the multiple disjoined structures of the conductive layer from a corresponding opening, 
 wherein each of the openings is disposed between two adjacent ones of the sidewalls, and 
 wherein each of the first dielectric layer and the second dielectric layer is either a uniform monolithic structure or a multi-layered structure. 
 
 
     
     
       2. The energy-efficient signal-transparent window assembly of  claim 1 , wherein a portion of the window substrate between the two adjacent ones of the sidewalls is exposed. 
     
     
       3. The energy-efficient signal-transparent window assembly of  claim 1 , wherein a portion of the window substrate between the two adjacent ones of the sidewalls is planar. 
     
     
       4. The energy-efficient signal-transparent window assembly of  claim 1 , wherein each of the sidewalls extends over a corresponding edge of the multiple disjoined structures of the conductive layer. 
     
     
       5. The energy-efficient signal-transparent window assembly of  claim 1 , wherein one component of the sidewalls is formed by the barrier layer. 
     
     
       6. The energy-efficient signal-transparent window assembly of  claim 1 , wherein one component of the sidewalls is formed by the second dielectric layer. 
     
     
       7. The energy-efficient signal-transparent window assembly of  claim 1 , wherein the sidewalls are formed by both the barrier layer and the second dielectric layer. 
     
     
       8. The energy-efficient signal-transparent window assembly of  claim 1 , wherein the barrier layer has a thickness, separate from the conductive layer, of at least 0.3 nanometers. 
     
     
       9. The energy-efficient signal-transparent window assembly of  claim 1 , wherein the second dielectric layer has a thickness, separate from the conductive layer, of at least 2 nanometers. 
     
     
       10. The energy-efficient signal-transparent window assembly of  claim 1 , wherein:
 the energy-efficient signal-transparent window assembly comprises patterned portions and non-patterned portions, 
 the patterned portions are defined by the conductive layer being formed by the multiple disjoined structures defined and separated by the openings, 
 the non-patterned portions are defined by the conductive layer being continuous between adjacent ones of the patterned portions, and 
 the non-patterned portions has a width, at least in one direction, of less than 50 centimeters. 
 
     
     
       11. The energy-efficient signal-transparent window assembly of  claim 1 , wherein:
 the energy-efficient signal-transparent window assembly comprises patterned portions and non-patterned portions, 
 the patterned portions are defined by the conductive layer being formed by the multiple disjoined structures defined and separated by the openings, 
 the non-patterned portions are defined by the conductive layer being continuous between adjacent ones of the patterned portions, and 
 an area of the non-patterned portions is at least 20% of a total area of the window substrate. 
 
     
     
       12. The energy-efficient signal-transparent window assembly of  claim 1 , wherein:
 the multiple disjoined structures are defined and separated by openings forming a pattern, and 
 each of the multiple disjoined structures has a width of between 0.05 millimeters and 5 millimeters. 
 
     
     
       13. The energy-efficient signal-transparent window assembly of  claim 12 , wherein each of the openings has a width of between 0.1 micrometers to 20 micrometers. 
     
     
       14. The energy-efficient signal-transparent window assembly of  claim 12 , wherein the openings form a pattern of parallel lines. 
     
     
       15. The energy-efficient signal-transparent window assembly of  claim 1 , further comprising a protection layer disposed over the window substrate, the sidewalls, and the multiple disjoined stacks formed by the first dielectric layer, the conductive layer, the barrier layer, and the second dielectric layer. 
     
     
       16. The energy-efficient signal-transparent window assembly of  claim 15 , wherein the protection layer has a thickness of greater than 10 nanometers. 
     
     
       17. The energy-efficient signal-transparent window assembly of  claim 1 , wherein the barrier layer further comprises at least one of chromium and niobium. 
     
     
       18. The energy-efficient signal-transparent window assembly of  claim 1 , wherein the window substrate comprises glass or plastic. 
     
     
       19. The energy-efficient signal-transparent window assembly of  claim 1 , wherein
 the first dielectric layer is a multilayered structure comprising multiple layers, and 
 the multiple layers form a stack and have different compositions. 
 
     
     
       20. The energy-efficient signal-transparent window assembly of  claim 1 , wherein:
 the second dielectric layer is a multilayered structure comprising multiple layers, and the multiple layers form a stack and have different compositions.